Aerospace Technic and Technology

The method of computational fluid dynamics (CFD) for the supersonic nozzle SK-20 of the low-pressure cold gas-dynamic spraying equipment DYMET-405 was applied for calculation of particles impact temperature and velocity. The application of the CFD method is the one-dimensional isentropic gas-dynamic model considers the flow only along the nozzle axis, without taking into account the heat exchange with the nozzle and the friction losses on the internal walls, which leads to obtaining overestimated results of calculations. Previously it was found out that the difference in the values obtained by numerical simulation and the results of calculations of a one-dimensional isentropic model was less than 10%. Numerical simulation of the two-phase flow of the cold spray process has been performed using the Ansys Fluent Academic software package. The influence of the initial cold spray process parameters such as temperature and pressure at the nozzle inlet on the change in temperature and velocity of aluminum particles with a diameter of 25 μm at the moment of impact with the substrate has been studied. Also, the influence of the particle size on the above-mentioned parameters has been obtained. The numerical simulation results of the particle impact temperature with the substrate have been used to calculate the critical velocity of aluminum powder – the velocity needed for coating formation. It is known that the formation of cold spray coatings depends on the velocity of the powder particles. For each material, there is a critical velocity at which the process of forming the coating begins. At particle velocities above the critical one, their adhesion to the substrate and the formation of the coating, due to the plastic deformation of the particles, occurs, while at lower velocities the surface erosion or deposition with low efficiency under certain conditions is observed. As a result of simulation and calculations of the critical velocity, the window of spraying was developed, that is the region of values of velocities and temperatures of the particles of aluminum powder, depending on the temperature and pressure of the air at the nozzle inlet, at which the formation of coatings is possible.

cold gas-dynamic spraying; coatings; spraying parameters; particles temperature and velocity; critical velocity; window of spraying

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